Saya what?

Richard338

Richard338

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Joined
May 3, 2005
Messages
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I made a few small steps of progress on my katana, making a saya from poplar and oak.
My blade is 3/16" thickness so I used 3 poplar boards of 1/4" thickness. I figured I'd try the easy route compared to chiseling out two halves. I traced the blade and cut out the profile from the middle piece. Then I glued the bottom panel on. Luckily I tested the fit before gluing on the top. It wouldn't fit in and out of the channel until I relieved a few areas by filing. Next to make the fit a bit more snug, I put 1/16" veneer on a channel tracing on the top piece before gluing it on. Then I fitted an oak piece to the shape of the habaki and attached it with glue and pins.

The photo below shows how the blade fits in snugly right to the back of the habaki. The blade clicks nicely into place so I got lucky with the fitting and depth.
Next comes some sanding and lacquering...
QB7To4R.jpg

vtGErgd.jpg
 
Better than my first saya.
Some observations:
The kurigata looks a bit frail and oversize. A grainy wood like you used will easily break. Buffalo horn is the standard material. Micarta works well,too. The hole through it is normally a fairly flat D-shape, yours it pretty tall. The inside of the kurigata is often lined with a metal sleeve called a shito-dome. This strengthens the kurigata. It can be skipped on a good solid kurigata. The sageo is wrapped through and on both sides of these parts.

The koi-guchi is usually something like buffalo horn, too. If wood is used, it should be tight grain. Oak is a poor choice due to the tanins, which may cause the blade to rust/corrode. Oak tends to split easily, too.

A kojiri on the end adds to the optical balance as well as protects the end. This is usually the same material as the koiguchi and kurigata ... buffalo horn. As mentioned before, micarta ( linen) works well.

I posted this this morning, but it never loaded????
 
Good points Stacy.
I made the kurigata out of stabilized redwood and it doesn't feel too flimsy, but I do have a piece of Buffalo horn.
I figured since the saya is entirely external to the sword, that this might be a practice run...
It looks a bit better with a few coats of lacquer.
What I'm most pleased with is the nice snug fit.
6nGi3F5.jpg
 
As I said, it looks good. I was only giving some of the classic details. There are no saya police who will come and tell you how to make your saya. Having fun is what is most important.
 
Thanks, and I hear you about having fun. I'm in the home stretch of this one now as I started fitting up the handle pieces today. Just some rayskin wrap and ito to go.
I think my next project will be a 4" drop point hunter...that will be fun.
 
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